Enhancing Aluminum Scrap Sorting with Handheld XRF

Transcription

1 Enhancing Aluminum Scrap Sorting with Handheld XRF Jonathan Margalit, Ph.D Business Development Manager Metals Thermo Scientific Portable Analytical Instruments 5 th Aluminium Sectional Forum Guangzhou, China September, The world leader in serving science

2 Presentation Outline Introduction Major Developments in the Aluminum Industry Handheld XRF-Basics and Developments The Value Proposition: Manufacturers Scrap Yards Conclusion 2

3 Did You Know That Aluminum was classified as a precious metal during the mid 19 th century. Napoleon III gave aluminum cutlery to his most distinguished guests, the rest had to eat with gold cutlery Once the Hall-Hѐroult process was commercialized the price of aluminum plummeted from $500/lbs 0.25$/lbs. X 3

4 We Are the World Leader in Serving Science We are the leading provider of analytical instruments, equipment, reagents and consumables, software and service for research, analysis, discovery and specialty diagnostics Global Scale 39,000 employees in 40 countries $12 billion in annual revenues Unparalleled commercial reach Unmatched Depth Innovative technologies Applications expertise Laboratory productivity partner Leading Brands We enable our customers to make the world healthier, cleaner and safer 4

5 Portable Analytical Instruments Molecular analysis Leading field-deployed analytical instruments for human health and public safety, delivering lab-accurate analysis at the point of need Elemental analysis The pioneer in x-ray fluorescence (XRF) analysis, bringing the lab to the field with speed, accuracy, and ease of use Stats: More than 400 employees worldwide Headquartered near Boston, USA Analyzer excellence recognized globally Molecular More than 6,000 instruments deployed since 2005 Elemental More than 35,000 analyzers deployed since

6 Key Developments in The Aluminum Industry 1) Increased demand for aluminum Industrialization in emerging markets Automotive: increased build rates and increasing light content (energy efficiency) Consumption forecasted to grow by 6% worldwide, propelled by strong growth in China 2) Primary production constraints Growing demand growing profits 25-30% of current production breakeven point Oversupply (5 mill. t stockpiled 75,000 Boeing 747s**) Lower output (example: Rusal lowering output by 7% this year**) 3) Strong push to incorporate scrap as a raw material Financial: 95% energy savings Environmental: 95% green house emissions reduction Regulatory compliance (LEED, CAFE) Growing environmental awareness Aluminum is 100% recyclable with no loss of quality 6 * Shipments of aluminum extruded products, The Aluminum Association **

7 3: Increased Demand for Secondary Aluminum 50% Since 2001 the production of secondary aluminum has exceeded that of primary aluminum. * Source: Aluminum Statistics U.S. Geological Survey, October

8 Novelis: An Example for Higher Scrap Integration 100 Content of Recycled Materials % from postconsumer scrap From Novelis website, red arrow added by author Benefits to Aluminum Manufacturers: Reduce dependence on mining and primary production Reduce carbon footprint Increase profitability Scrap Trends: Higher recycling content Higher post-consumer scrap content Cross sector competition for scrap 8

9 4: The Role of Secondary Aluminum is Shifting The usage of secondary aluminum is shifting: Primary and remelted billet are completely interchangable *..as long as the proper raw materials are used to achieve the necessary chemistry and specifications Secondary aluminum could be used not just for castings, but also for painted automotive sheet **..if the aluminum scrap is properly segregated *** *According to US billet remelter, quoted from Metal Bulletin, November 2012/Number 9178 ** According to Charles Bradford, Bradford Research, quoted from Metal Bulletin, November 2012/Number 9178 *** According to Kay Meggers, Alcoa, quoted from Metal Bulletin, November 2012/Number

10 Norsk Hydro Where s the Problem? Replacing Alumina with Scrap Feed Material: Information availability about: Manufacturer Composition Lot Information Country of Origin Knowledge of Hazardous Materials With XRF???? 10

11 Handheld XRF Technology Overview 1. Primary x-ray ejects K-shell electron 2. Electrons from higher shells fill in the gaps 3. Differential energy state is released as fluorescence x-rays (element-specific) 4. The x-ray energies are analyzed and compared with a built-in alloy library 5. Output: - Spectra - Positive grade identification - Elemental composition - Match level (0-4) 11

12 12 Detectable Elements Using Handheld XRF Then

13 Latest Detector Technology: the Silicon Drift Detector Similar to Si PIN, but larger surface area, higher quality Si, low leakage current, small anode capacitance, and unique electrode array This means that the detector has: Higher count rate No detector dead-time Higher resolution Improved signal-to-noise ratio Better efficiency, sensitivity, precision GND C1 drift field -V C2 Anode U BACK Homogeneous thin entrance window 13

14 14 Detectable Elements Using Handheld XRF Now

15 The Result: In-Family Grade Separation Capabilities: Si Fe Cu Mn Mg Min Max Min Max Min Max Min Max Min Max Faster separation based on light element content - in air 15 *Not all elements shown

16 Early Stage Material Qualification Bulk scrap Inspection/ Sorting Pretreatment Melting-Holding- Homogenization Furnaces Final product End-product specs Equipment integrity Contaminant prevention Regulatory compliance Melt feedstock optimization Advantages: 1. Quick transactions with scrap dealers 2. Portability: bring the analyzer to the scrap 3. No specialized technical skills required 4. Save on lab turnaround time 16

17 Maximizing Savings and Profitability 6061 or 6063? What a difference a grade makes 4 cm Annual Turnover ( ooo tons) Potential Cost Savings as a Result from Correct Grade Identification Price Difference ( ) USD/lb $0.05 $0.07 $ $2.6 M $3.7 M $5.2 M 12 $1.3 M $1.8 M $2.6M 6 $0.6 M $0.9 M $1.2M 17

18 Application Example: Melt Feedstock Optimization 3105 can be made by using various alloy combinations: A B C n % 37% 30% % 37% 51% % 26% 19% Within 3105 Spec? 3105 Relative Material Cost: 1X 1.08X 1.11X Most Cost-Effective Combination 18

19 Conclusion Aluminum scrap is becoming a strategic raw material. The portion and role of post-consumer scrap are shifting. There is a growing need to characterize this new raw material. Thanks to technological advancements in handheld XRF, light element measurement capabilities (Mg, Al, Si, P, S) have improved significantly. Handheld XRF is a value-added tool, currently used by aluminum manufacturers and scrap yards operators to determine alloy grade and chemical composition. 19

20 Thank You Q&A Jonathan Margalit Thermo Fisher Scientific Tel.: +1 ( 978)